Sulphur-coke composition



seemed Mar.3,.1925.

UNITED STATES PATENT OFFICE.

HARRY A. NO'YIES, OF GREENWICH, CONNECTICUT, ASSIGNOR TEXAS GULF SUL-PHUR COMPANY, OF BAY CITY, TEX AS, A CORPORATION OF TEXAS,

SULPHURCOKE COMPOSITION.

No Drawing.

vision of an improved composition com- 1 posed for the most part ofsulphur and coke.

By sulphur-coke composition I mean a.

composition composed principally of sulphur and finely divided coke, thecoke being distributed substantialy uniformly throughout the'sulphurini'a 'molten state and the resulting mixture solidified by casting, or

otherwise, to form the composition. Such sulphur-coke compositions areuseful in the arts and industries for making objects of art, tanks,troughs, tubs, pipes,- insulating blocks, and so on, and are of especialadvantage where resistance to acid liquors or fumes is desired.

Sulphur compositions composed for the most part ofsulphur and finelydivided carbonaceous materials, such as coal or raphite, are not inthemselves new.- 1 have found, however, that sulphur-coke compositionspossess advantageous properties that combined in. equivalent manner withsulphur. This may be 'due to the irregular, porous structure of coke.The sulphur-coke composition of my present invention is strong, durable,acid-resistant and can be reliably made of uniform character andproperties.

The percentage (by .weight) of sulphur in the improved composition ofthe invention may be varied from about 75% down to about 40%, and,correspondingly, the percentage (by weight) of coke may be varied fromabout 25% up to about 60% I prefer, however, to employ from 60 to (byweight) of sulphur and from 40 to (by weight) of coke in making theimproved composition of the invention, and my usually referredcomposition contains approximate y four parts, by weight, of

are not obtainable when coal or graphite are Application filed August 5,1924. Seriai No, 730,209.

sulphur to approximately three parts, by weight, of coke. Thecomposition when molten should be fluid enough to pour and flow freelyand in this molten state resembles in a general way molten. lava.

I have discovered that the size of the coke particles and the relationof the different sized particles to each other have a marked influenceupon the ultimate properties of sulphur-coke compositions. Thus, I havefound, that a certain composition containing approximately fourv parts,by weight, of sulphur and three parts, byfweight, of coke of aparticular and substantially uniform degree of fineness is not strongenough for commercial fabrication and use, and, moreover, loses strengthon ageing. however, the size of thepartieles of the coke content of thiscomposition be proportioned in accordance with the principles of mypresent invention, the vresulting; sulphurcoke composition is strong,durable and does not deteriorate with age.

I have discovered that the important consideration in, makingsatisfactory compositions of sulphur and coke is to 'havetheproperdegrees of fineness of the coke particles, as well as the properproportions of sulphur and oke. Having established these conditions, i.'e., the pro er degrees of fineness of the coke partic es and the properproportions of sulphur and coke, additional amounts of finely divided orcoarsencoke may be added as a filler, or as a reinforcing agent, or forthe purpose of giving the composition (in the molten state) the desiredconsistency for handling or pouring.

The improved conposition of the invpnin its preferred form, may containas high as 60 parts of sulphur i0 40 parts of coke, by-weight, or as lowas 45 parts of sulphur to 55 parts of coke. The difi'erence in the.relative amounts of sulphur and coke employed in making the compositionof the invention depends principally on the amount of coke required toobtain the necessary proportions of coke particles of the proper sizesfor body, strength and durability of the product. proximately'four partsof sulphur by weight to three parts of coke by weight. In accordancewith the preferred form of thepresent invention, the coke mayconveniently be all finer than '10 mesh (Tyler standard), with My usualproportion is ap roughly two-thirds of its weight fine enough totwo-thirds of that which passes the 100- mesh screen fine enough to passa 200 mesh to pass a 100 mesh screen and from one-half screen. v

The following examples will serve to illustrate the novel features of.the invention:-

(1) A sulphur-coke composition made up of about four parts of sulphurand three parts of coke ground to pass a sieve of 200 meshes to the inchwas found to have an avera e initial tensile strength of about 150 pouns per square inch and an average tensile strength of only 28 pounds persquare inch after standing for six weeks. On longerstanding its tensilestrength became substantial] negli ible. (2) A sulphur-c0 e compositionmade u of around (within three parts of su phur and two parts of cokebreeze had an initial tensile strength of from 400 to 500 pounds persquare inch, but on standing or ageing for a. few weeks the tensilestrength became substantially lower. The coke breeze employed in thisexample had the following screen analysis:

(3) A sulphur-coke composition made up as in the preceding example,using for the coke a mixture containing 80% of coke breeze having theforegoing screen analysis and of coke-passing a 200 mesh screen,

"had a tensile strength averaging from 600' to 700 pounds per squareinch. Further small changes in the proportions of the par- 1 ticles iiithe coke mixture gave a composition with a tensile strength ofapproximately 1000 pounds per square-inch.

Thefsulphur-coke co-mpositionof the invention contains by weight from 75to 40% of sulphur and from to v60% of coke, the coke being of suchfineness that from 25 to 75% thereof by Weight passes through (and thebalance remains on) a 100 mesh screen, and of the part passing throughthe 100 mesh screen from to 75% thereof byweight passes through (and thebalance re- -mains on) 'a 200 mesh screen. Conveniently, substantiallyall of the coke is finer than 10 mesh.

As a specific example of the invention, I mention the followingcomposition which I have found to possess excellent properties'i Pounds.Sulphur; Coke breeze having approximately the screen analysishereinbefore given A 28 Coke through 200 mesh 10 to 11 Coke through 150mesh on 200 l mesh to Coke through 120 mesh on 150 mesh to Coke through100 mesh on 120 mesh to Several procedures maybe followed in making thesulphur-coke composition of the invention. These procedures will besomewhat dependent upon the size of the container used, the source'andamount of heat,

the ,method. of mixing, the moisture in the sulphur orcoke, and therapidity with a which the moisture is driven off. One prosprinkled overa suitable surface, such asa floor, conveyor belt, and the like, Whereit solidifies in small lumps andfragments resembling frit material. Thislum or frit Per cent. On 10 mesh screen 1. 4; s mix g ther (dry) theproper Th 10 h Screen on 40 h materials sothat when all or a unit ofthis screen 3& m1xture is melted, heated, and mixed the Thru 40 meshscreen on 60 mesh P p P i 9 l s, An her proscreen 23,4 f e i8 0 melt theSulphur and to then Th 60 h screen on 0 h stir in the coke continuingthe heating and screen 10, 5 'l g f QI he mixture is complete until Th80 h screen on 100 e h 4 the molst-ure, the occluded air and otherscreen 10. 5 g fl d n ff- Another procedure is Th 100 h screen on 120 hto dry the sulphur and the coke in any conscreen 5,0 ven ent manner andthen to melt, heat and Th 120 h Screen on 150 1 mix them together.Another method is to screen f, 2, 6 heat h coke first and stir'thesulphur int Th 150 h screen on 200 h the, coke with proper heating.Another screen 1.4 d, is t0 melt tOgether the whole or a Th 200 h partof the sulphur to ether with the Wliole material may be bagged or binnedor transportation or storage,.as desired.

The tem era ture of heating in making or .recasting t 0 improvedcomposition of the I invention Imam be just above. the melting;

size of the heater, the

ing but maybe recast from one shape to another, as desired. This. meansthat it may stay in one cast shape indefinitely'or that the samematerial may comprise the whole or part of several castings 'or'objectsinside of a few days, months or years.

From the foregoing description, it will be I understood that thepresent. invention contemplates a sulphur-coke composition in which thecoke content thereof is of various determined degrees of fineness. JustWhy it is necessary to have a certain proportion of relatively very finematerial and a certain proportion of relativelyv coarsematerial withsome material inj-between these two degrees of fineness, I am not atpresent prepared to say. Asthe result of an extended and carefulinvestigation, I have found that these conditions are necessary withrespect to the coke content of a satisfactory sulphur:

. coke composition, and it is my purpose herein to protect this propersizing of, the particles ofcoke used for the .production of superiorsulphur. and coke compositions that are acid resistant and useful in thearts and.

I industries. It is apparent that I may-vary the composition somewhatfrom time to time on the basis of thediiference in area of the surface.of the particles making up the proper proportion of coke but carryingthe gradatio'in of the particles necessary for the proper "composition.In making the improved sulphur-coke compositions of thei'nvention, Igenerally use sieved, ground or crushed coke of the proper sizings. Imay if desired, include an appropriate amouht of coke breeze, .orotheravailable form of finely divided. coke, on the basis of its sieveor screen analysis.

Petroleum coke (substantially free iron) and coke screenings. (notnecefiarily' allcoke) may beincluded' in the totil coke content of thecomposition the basisgof their respectivescreenanalysis. 1

Reinforcing agents, such A as expanded metal lath, reinforcing-wire orrods, metal .screen cloth, etc., ma if 'desired be incorporated orembedde the sulphur-coke composition, particularly when employed in theconstruction of tanks and the like where-- maximum strength is desired.

-I'claim:-. J. 1. A sulphur-coke compositionfcontaining by weight fromto 40% of sulphur and from 25 to 60%"of coke, the coke being of balanceremains on a 200 mesh screen.

2. A sulphur-coke composition containing which passes the 100 meshscreenfine enough approximatel of that which passes the 100mesh'screenfine enough to pass a 200 mesh screen. i '6'.- A sulphur-cokecomposition containing weight being fine-enough 100 mesh screenon 'w ichthebalance'remains and of the part. through the 100 mesh screen from40-to 75% the eof"by weight being fine enough to pass. hrough a 200 suchfineness that from 25 to 75% thereof by weight passes-through while thebalance remains on a 100 mesh screen and of the part through the 100meshscreen from 40 to 75% thereof by weight passes through while the byweight from 75 to 40% of sulphur and from 25 to 60%, of coke, the cokebeing of such fineness that approximately two-thirds of its weightpasses through and the. bal-' ance remalns on a 100 mesh screen and ofthe part through the 100 mesh screen approximately one-half totwo-thirds thereof passes through and the balance remains on a- 200 meshscreen.

3. A sulphur-coke composition containing by weight from 75 to 40% ofsulphur an from 25 to 60% of coke, the coke being substantiallyall finerthan 10 mesh and from 25 to 75% thereof by weight being fine enough toass through'alOO mesh screen on which the alance remains and of the artthrough the 100 mcshscreen from 40 to 75% thereof by weight being fineenough to pass through a 200 mesh screen on which the balance remains.

4. A sulphur-coke composition containin by weight from 75 to 40% ofsulphur an from 25 to 60% of coke, the coke bein substantially all.finer than 10 mesh wit approximately two-thirds of its weight 'fineenough to pass a 100 mesh screen and ap proximatelyone-half totwo-thirds ofthat to pass a 200 mesh screen.

=5. A sulphur-coke composition containing four parts of sulphur byweight and t we parts of coke by weight, the coke being substantiallyall finer than 10 mesh with 3 approximately two-thirds of its weightfine enough to pass a l00 mesh screen and approximately one-half totwo-thirds approximatel four parts of sulphur -by weightjf-and teel-partsof coke lizlw'e ht,. th'e' ':fflike being'substantially aller'tan 10. mesh and fnomfl25 to 75% thereof by mesh screen on 'which thebalance remains.

7. "Asulphur-coke composition containing I by weight from; 75 to 40% ofsulphur an from 25 to 60% of coke, the coke being made up ofapproximately 60 to'80% ,of coke 12 5 breeze, togetherwithj at least 20%of fine coke passing a2001'nesh screen.

8. A sulphur-coke compos'itlon containing approximately four gparts ofsulphur by weight and three parts of coke by weight, 1300- to ,passthrough V a approximately two-thirds by weight of the from 25 to 75% byweight of the coke being 19 coke being fine enough to pass a 100 meshfine enough to pass through a 100 mesh screen and approximately one-halfto twoscreen on which the balance remains and thirds of that whichpasses the -100 mesh from 4:0 to 75% of that which passes the 100.screen being fine enough to passe 200 mesh mesh screen being fine enoughto pass 21v 200 screen. mesh screen. 4

9. A sulphur-coke composition containing In testimony whereof I afiix mysignaapproximaitely foin' parts of sulphur by ture. weight and threeparts ofcoke by -weight, HARRY A. NOYES.

